motor workshop presentataion files. english

© ABB| Slide 1

ABB Technical Workshop on Motorsand Generators

Discrete Automation and Motion Division, May 27 2015

May 26, 2015

© ABB| Slide 2

AgendaChương trình

May 26, 2015

Time - Thời gian Content - Nội dung08:30 – 09:00 Registration - Dong Nai Meeting Room - 12B Floor - Khách mời đăng kí - Phòng Đồng Nai - Tầng 12B

Tòa nhà REE9:00 – 09:15 Opening speech - Introduce VNABB - Discrete Automation and Motion Division- Motors and Generators

Business Unit Phát biểu mở đầu chương trình - Giới thiệu ABB Việt Nam-Ban Thiết bị Tự động hóa vàTruyền động Điện- Bộ phận Động cơ

9:15 – 10:45 Basic motor technical information + ABB safe area motors portfolio - Kỹ thuật cơ bản động cơ điện +Động cơ điện không sử dụng trong vùng nguy hại

Basic hazardous area information + ABB hazardous area motors portfolio - Các loại động cơ & thông sốsử dụng trong môi trường nguy hiểm

10:45 – 11:00 Break - GIải lao11:00 – 12:00 MV motor information + ABB portfolio - Tổng quan về động cơ trung thế ABB11:45 – 12:00 Lunch - Buffet trưa13:00 – 13:30 ABB Drive - Biến tần ABB13:30 – 15:15 ABB Dimensioning Tools (MotSize+DriveSize) with exercises

Các công cụ đo lường kích cỡ biến tần, động cơ (Drivesize, Motsize)15:15 – 15:30 Break - Giải lao15:30 – 16:30 NEMA+ MPT + NEMA vs IEC + Service

Động cơ Nema + Sản phẩm truyền động điện cơ khi

Dịch vụ kỹ thuật

16:30 – 17:00 Q&A & wrap up - Hỏi đáp & Kết thúc chương trình

© ABB| Slide 3


May 26, 2015











© ABB| Slide 4

Introducing ABBRichard Yue, Discrete Automation and Motion Division, May 27 2015

May 26, 2015

A global leader in power and automation technologiesLeading market positions in main businesses

~140,000employees

Presentin

countries~100

Formedin

1988merger of Swiss (BBC, 1891)and Swedish (ASEA, 1883)engineering companies

In revenue(2014)

billion40$

© ABB| Slide 6

Power and productivity for a better worldABB’s vision

Update

A leader in addressing powerinfrastructure and control needsfor utilities, industry and transport& infrastructure

A leader in operational asseteffectiveness – uptime, speed,yield – and efficiency

Contributing to decoupling growth from environmental impact

§ Less energy per unit GDP§ Less pollution per unit energy

© ABB| Slide 7

How ABB is organizedABB Group: Five global divisions

$10 billion35,400 employees

Power Products


Power Systems


Discrete Automationand Motion

$7,5 billion29,900 employees

Low VoltageProducts


ProcessAutomation

(2014 revenues)

§ Electricals, automation, controls andinstrumentation for power generationand industrial processes

§ Power transmission§ Distribution solutions§ Low voltage products

§ Motors and drives§ Intelligent building systems§ Robots and robot systems§ Services to improve customers’ productivity

and reliability

ABB’s portfolio covers:

ABB Vietnam Introduction

§October 31, 2013

ABB in Vietnam

© ABB GroupMay 26, 2015 | Slide 9

4 Divisions:

• Power Products

• Low Voltage Products

• Discrete Automation and Motion

• Process Automation.

§ Headquarters: Hanoi§ Orders 2014: 144 MUSD§ Revenues 2014: 153 MUSD§ Total Workforce: Over 850

Hanoi

HCMC

Bac Ninh

Da Nang

VNABB is one of the Top 20 companies to work for in Vietnam.In the category Engineering VNABB is #3Source: Anphabe – Vietnam online Network of Management Professionals

ABB in VietnamBusiness Profile

§ DM and LP are growing fast and promising§ PA is growing and the potential market is

significant

§ Factories:§ Transformers SPT: Power transformers up to 63MVA§ Transformers DT: Distribution transformer up to

12.5MVA§ High Voltage: Interrupters and Spacers§ Medium Voltage: MV switchgear (ZS1) and Compact

Secondary Substation (CSS)

Discrete Automation and MotionDriving customers industrialproductivity and energy efficiency

October 31, 2013

Business units and offering

§ Low voltage AC drives from0.12 to 5600 kW§ ServoDrives and controls,

linear Motors§ Medium voltage drives from

315 kW to more than 100 MW§ DC Drives from 4 kW to 15000

kW§ PLCs, HMIs§ Software tools§ Product Packages Based on

Drives and PLC offerings§ Service

Drives and Controls

§ Low voltage motors from 0.25to 1000 kW§ High voltage motors and

generators up to 70 MW§ High speed motors§ Traction motors§ Wind power generators§ Diesel generators§ Gas and steam turbine

generators§ Hydro generators, tidal waves§ Mechanical power transmission§ Service

Motorsand Generators

§ Excitation and synchronizingsystems§ High power rectifiers§ DC wayside power solutions§ Power quality and power

protection products, includingUPS§ Traction converters§ Wind turbine converters§ Solar inverters§ EV charging infrastructure§ Service

Power Conversion

§ Industrial robots§ Robot controllers and software§ Industrial software products§ Application equipment and

accessories§ Robot applications and

automation systems forautomotive, foundry,packaging, metal, solar, wood,plastics, etc. industries§ Service

Robotics

October 31, 2013

Which market do we serve?Over $ 130 billion market

Discrete manufacturing Hybrid/batch manufacturing Process industries Utilities

Transportation equipment Infrastructure, buildings Electric vehicles Renewable energy

2013 global market value in US$ million

$42,162 $10,556 $33,145 $11,113

$15,551 $7,614 $385 $10,698

BU Motors and Generators

April 9, 2015

© ABB| Slide 15

What we stand for

We are to be the best - as determined by our customers -marketers, designers and manufacturers of industrial electricmotors, generators and mechanical power transmissionproducts.

With expertise, and a comprehensive portfolio of productsand life-cycle services, we help value-minded industrialcustomers improve their energy efficiency and productivity.

Our beliefs

© ABB| Slide 16

§ Employees About 16,000

§ Presence More than 100 countries

§ Manufacturing 41 factories in 11 countries

§ Service 65 ABB service centers and more than100 authorized service providers

§ Channels 5,600 ABB external channels

§ Stocks 1,600,000 products in 7 logistic centers

April 9, 2015

Who we areBusiness unit Motors and Generators

© ABB| Slide 17

What we doComplete product offering – one place to buy

April 9, 2015

§ Low voltage high efficiencymotors

§ High voltage induction andsynchronous motors

§ Motors for explosiveatmospheres

§ Permanent magnet motors§ DC motors§ Traction motors§ Motors for marine applications§ Synchronous reluctance motors§ Servomotors§ Motors for variable speed

applications

IEC motors

§ Induction and synchronous windpower generators

§ Synchronous generators fordiesel and gas engines

§ Synchronous generators forsteam and gas turbines

§ Synchronous generators formarine applications

§ Synchronous generators forindustrial applications

§ Synchronous condensers forreactive power compensation

§ Traction generators

Generators

§ Low voltage high efficiencymotors

§ High voltage induction andsynchronous motors

§ Motors for explosiveatmospheres

§ Permanent magnet motors§ Washdown motors§ DC motors§ Traction motors§ Motors for marine applications§ Servomotors§ Motors for variable speed

applications

NEMA motors

§ Mounted bearings§ Enclosed gearing§ Mechanical drive components§ Couplings§ Sheaves and bushings§ Conveyor components§ Geared motor units

Mechanical powertransmission products

© ABB| Slide 18

What we do…supported by world class services

April 9, 2015

Faster start-up, optimized life cyclemaintenance and early detection ofpotential faults

§ Certified, experiencedcommissioning engineers

§ Proven four-level maintenanceprogram

§ Remote and on-site conditionmonitoring solutions

§ Regular health checks for criticalequipment

Increased availability and minimizeddowntime

§ Genuine OEM spare parts andsupport

§ Efficient on-line order processingand tracking system

§ Individual components, tailoredpackages and maintenance kits

§ Support in rationalizing on-sitespare part stocks

Improved efficiency, reliability andsafety

§ On-site and workshop repairs byfully trained personnel

§ Direct replacements for olderunits

§ Upgrades of old equipment withlatest technology

§ Turnkey component upgrades§ Local support through global

service organization

Maximized performance, reducedrisk and delivered know-how

§ Analyze energy, performanceand reliability costs

§ Support for long-term planningincluding risk assessments andtraining programs

§ Access to ABB’s extensiveknowledge base

§ Single agreement for easymanagement

Installation,commissioning,maintenance and

condition monitoring

Repairs, replacements,upgrades

and refurbishmentSpares and consumables

Advanced services,trainings and

service agreements

© ABB| Slide 19

Our products work in all industries, all applications

April 9, 2015

© ABB| Slide 21


May 26, 2015











BU Motors and GeneratorsBasic Motor Technical &Non-Hazardous Area Motors Portfolio

Chiam Chee Seong27th May 2015

© ABB BU Motors and GeneratorsMay 26, 2015 | Slide 22

Component Parts of a Motor

Stator house

Rotor

Shaft

D-End-shield+bearingN-End-shield+bearing

Terminal cover

Fan

FancoverTerminal block

Stator winding

Stator core


Terminal box

The Making Process

Stator manufacturingPunching Rotor casting

Coupling Stitching

Rotor assembly

Assembly

Winding

Packing

ImpregnationTesting


In a LVAC electrical motor there are

§ Wire insulation (Enamel Insulation)

§ Slot insulation

Insulation


Insulation (Cont.)

§ Slot cover or slot wedge

§ Phase insulation


Insulation (Cont.)

§ Layer insulation

§ Tying or lacing band


ImpregnationTrickle impregnation (applied on frame 280 and above)

Stoving:Temperature of the stove150oC, stoving time 50 min

Heating during rolling:20°C/min, temperature in theend of the rolling 130 - 140°C(epoxy 160°C)

§© ABB BU Motors and GeneratorsMay 26, 2015 | Slide 28

ImpregnationVacuum impregnation (applied on frame below 280)

Vacuum sucks the resin intowindingImpregnation time 45 minNo heating duringimpregnation

Stoving:Temperature of the stove140oC, stovingtime 4 h


IEC Motor Mechanical Design

Frame Construction

Ø Modern totally enclosed squirrel cage motors are available in a choice ofaluminum, steel and cast iron frames for different application areas.

Ø Available frame materials for ABB motors are cast iron and aluminium.

Frame Size- The height of shaft center point in

relation to the surface of the ground(typically measured in mm).

- Common IEC frame sizes for LVmotors are 56, 63, 71, 80, 90, 100, 112,132, 160, 180, 200, 225, 250, 280, 315,355, 400 and 450.


Mounting Arrangements

- There are Code I and Code IIfor motor mountingarrangements. Marked *)means it’s not specified in IEC60034-7.

- Mounting arrangement is veryimportant to manufacturer asthere might have some specialconsideration requiredespecially for vertical mountedmotors (eg: V3, V6, V1….)

- Special end shield or seals isrequired for those shaftupwards where water/liquidare expected to go down alongthe shaft.


Cooling Type

§© ABB BU Motors and GeneratorsNovember 4, 2010 | Slide

Cooling Type (Cont’)

§© ABB BU Motors and GeneratorsNovember 4, 2010 | Slide

Degree of Protection (IP/IK)


Terminal Boxes


Bearings

- ABB’s LV motors are provided with deep groove ball bearings as standard. Thecomplete bearing designation is stated on rating plate of most motor types.

- Bearing selection is based on forces from load towards to bearings (eg: axial force,radial force and thrust force). It’s advisable to provide the force value, mounting ,direction and magnitude to ABB for precise verification.

- Common bearing selection on applications below:-Roller bearingà High radial force (eg: belt, conveyor…)Angular contact bearingà High thrust force (eg: vertical mounted..)

- The normal life L10 of a bearing is defined, according to ISO, as the number ofoperating hours achieved or exceeded by 90 per cent of identical bearings in a largetest series under certain specific conditions. 50 per cent of the bearings achieve atleast five times this figure.

- Insulated bearing is needed for VSD motors, please refer to VSD section for moreinformation.


Enclosure Surface Treatment and Colour

- All the painting system are according to ISO/EN 12944 standard.- ISO/EN 12944 divides durability into 3 categories: Low (L), Medium (M), and High

(H) where Low (L) durability corresponds to 2-5 years, Medium (M) 5-15 years andHigh (H) more than 15 years.

- All the ABB motors are treated with Medium (C3M) surface treatment and MunsellBlue 8B 4.5/3.25 paint colour as standard. Others painting systems are availableupon request.


Vibration

- Vibration according to Grade A is applied to ABB motors as standard.

- The vibration measurement is performed for all motors and generators according toIEC 60034-14.

- Grade B vibration level is available upon request.


Basic Information for Dimensioning (DOL)

§ Supply: Voltage, frequency, and its variation

§ Load: Torque vs Speed curve, application, speed

§ Environment: Safe/Ex, ambient temperature, altitude

§ Standard/ specification: IEC/NEMA, Marine, and etc….

§ Additional requirements: Mounting, cooling, IP rating….


Terminology - Basic Formulas


Permissible Temperature Rise


Torque vs Speed Curve


Starting Type


BU Motors and GeneratorsVSD Motors

§ 65% of electricity used in industry isabsorbed by electrical motors

§ 20% of this energy is dissipated bylosses of electrical motors

§ The use of “best technology”(including high efficiency motors, useof drives etc.) would lead to areduction of emission of CO2 by 68%from 23,500 Mton/year down to7,500Mton/year


BU Motors and GeneratorsMajor Benefit of using VFD

§ PERFORMANCE CONTROL

• AC drives are used to bring process and quality improvements in industrialapplications through drives' control superiority in terms of key parameters includingacceleration, flow, monitoring, pressure, speed, temperature, tension and torque.

§ Energy Saving

• AC motor-driven applications that do not require full speed can save energy bycontrolling the motor with a variable speed drive.

• Energy cost saving with variable torque can be significant, often paying for the costof VFD within a matter of months for some specific applications(e.g. variablespeed fan, pump).


Made in ABBVSD motor characteristics - Comparison with constantspeed motor

Constant speed motors

• Starting current surge up to morethan 8 times nominal current, andhence a big voltage drop onnetwork. Sometimes thisphenomena might cause motorstarting failure or network black out

• Consideration of the heating duringstart is inevitable, and hence alimited number of consecutivestarts.

• Starting torque could be a problemsometimes for high load torque andhigh inertia application

VSD motors (Advantage)

§ Current will be well controlledaround nominal current, and hencemuch less impact to the network.

§ No extra attention needed for thethermal stress during starting, andno limitation on number ofconsecutive starts due to thermalproblem.

§ Starting torque is close to maximumtorque, making start easy


VSD motor characteristics - Comparison with constant speedmotor

Constant speed motors

• Having only one operating point(speed and power), hence, sizing ismade only to that one point.

• Sinusoidal input, no extra heatingdue to harmonic distortion.

• Sinusoidal input, no extrainsulation requirements due tovoltage peaks.

• Sinusoidal input, no extrainsulation for bearing needed.

• Sinusoidal input, noise levelrelatively low

VSD motors (Extra Consideration)

§ Having an operating range (speed andpower), hence, sizing is made to the wholerange, including the relationship betweencritical speed and the operating speedrange, and the need to enhance thecooling at low speed range.

§ Extra insulation might be needed due tovoltage peak

§ Extra insulation needed for bearingbecause of the shaft voltage caused by theinherent association with high frequencyvoltage

§ Might cause higher noise level hencemight need to consider noise control


Additional Consideration for VSD Driven Motors

Ø More Information of Variable Speed Operation

Ø Safe Area Motors’ Loadability & Cooling Type (Motor)

Ø Winding Insulation (Motor) and Filtering (Converter)

Ø Insulated Bearing (Motor)

Ø Hazardous Area (Motor)

Ø Hazardous Area Motors’ Loadability

Ø Others

© ABB BU Motors and GeneratorsNovember 4, 2010 | Slide

More Information for VSD Motors§ What is the load type/ application?

§ What is the operating speed range?

§ What is the VSD power required?

§ Is there any overload condition? If yes, what is the duration?

§ Which drive to be used?


Process performance motorsVSD - Loadability curves

§ Based on comprehensive tests

§ With separate cooling full 100%loadability possible also at low speeds

§ The curve shows loadability ofprocess performance motor onconverter duty as a relation to nominaltorque

§ This loadability curves represent onlythe thermal loadability. Other factorsmay also limit the loadability (i.e. themax. Allowed speed of the motor)

ACS800/50 Hz, temp rise B


Process performance motorsVSD – Insulation and filtering

Nominal supply voltage UNof the converter

Winding insulation and filters required

UN £ 500 V ABB Standard insulation

UN £ 600 V ABB Standard insulations with du/dt-filters atconverter output

OR

ABB Special insulation(variant code 405)

UN £ 690 V ABB Special insulation(variant code 405)

AND

du/dt-filters at converter outputUN £ 690 V ANDcable length > 150 m

ABB Special insulation(variant code 405)


What will Happen if Incorrect Winding Insulation Applied forContinuous VSD Application?


Insulated Bearing on VSD Driven Motor§ Common mode voltages of voltage source of converters are causing high

frequency bearing currentsINVER TE R

M O TO R C AB LE M O T O R GE AR LO A D

4

7

3 6 S haft g round ing cu rre nt

2 4High frequencyshaft vo ltage

H igh frequencyfra m e vo ltage

7

Com m on m od evo ltage pu lse

2

1

3

5 6

5High frequencycircu la ting current

-D C

+D C

1

1

High frequencycom m o n m odecurrent

P E-curren t

© ABB BU Motors and Generators May26, 2015 | Slide 54

Insulated Bearings and Filters

Nominal power PNand/or IEC frame size

Preventive measures

PN < 100 kW No actions needed

PN ³ 100 kWORIEC 315 £ Frame size £ IEC 355

Insulated non-drive end bearing(VC+701)

PN ³ 350 kWORIEC 400 £ Frame size £ IEC 450

Insulated non-drive end bearing(VC+701) ANDCommon mode filter at the converter

§ Use of non-suitable bearings, the surfaces of rolling elements and raceways in thebearing might be damaged and degrade the grease rapidly (electric erosion). This is alldue to common shaft current from converter supply.

§ Bearing voltages and currents must be avoided with insulated bearings (VC+701) and/orproperly dimensioned filters at the converter must be used as shown in guideline tablebelow:


Process performance motorsVSD – Insulated bearing

§ Bearing currents in VSD duty can damage thesurfaces of rolling elements and raceways in thebearing and degrade the grease rapidly (electricerosion)

§ Insulated bearing eliminates the bearing currents→ Longer bearing lifetime → less maintenance

§ Several hundred of tests at site show that it is onlyneeded on N-end

§ Outer ring plasma spray coated and further treatedto make it insensitive to moisture and humidity

§ Only high quality insulated bearings are used


Sample Damages of Shaft Current to ConventionalBearings


Process Performance Motors


Low voltageProcess Performance Motors

§ Motors for the most demandingcontinuous process applications

§ Tailor-made to meet the individualneeds of applications

§ Prepared to answer any reliability,availability and energy efficiencychallenge, both now and in the future.

§ Fulfilling IE2-IE3-IE4 efficiency class,available from stock*


* Depending on warehouse

Process Performance MotorsRangeSizes 71-45056 63 71 80 90 100 112 132 160 180 200 225 250 280 315 355 400 450

Process performance motors56 63 71 80 90 100 112 132 160 180 200 225 250 280 315 355 400 450

IE2 High efficiency aluminum motors (M3AA)

IE3 Premium efficiency motors M3BP (Aluminum M3AA <250)

IE4 Super premiumefficiency motors M3BP

IE2 High efficiency cast iron motors (M3BP)


IE2 aluminum – M3AA: Output 0.12 kW to 90 kW **

IE2 Cast Iron – M3BP: Output 0.25 kW to 1 MW **

IE3 Cast iron – M3BP: Output 0.75 to 375 kW **

IE4 Cast iron – M3BP: Output 75 to 375 kW ** ** Depending on pole number and frame size

General Performance Motors


§© ABB /BU Motors and Generators§May 26, 2015 | Slide 33

General Performance MotorsRange

General Performance MotorsCast Iron Motors

§ New optimized General Performance cast ironmotors cover the needs from various industrials,designed on global R&D platform with widervariants feasibility compared to existing units.This allows motors running on demanding VSDoperations.

§ Fulfilling IE2 efficiency class, premium efficiencyIE3 is available upon request.

§ Output 0.18 kW to 355 kW**Type M2BAXFrame sizes 71 to 355 Cast Iron

** Depending on pole number and frame size

© ABB I BU Motors and Generators

May 26, 2015 | Slide 34

§ General Performance IE2 high efficiencyaluminum motors, suited for applicationswhere simplicity and off-the-shelf availabilityare paramount. With ABB quality andsupport, these motors have the featuresappreciated by volume customers and serialOEM’s.

§ Fulfilling IE2 efficiency class, available fromstock*

§ Output 0.06 kW to 55 kW**Type M2AAFrame sizes 56 to 250 Aluminum

* Depending on warehouse** Depending on pole number and frame size

General Performance MotorsAluminium Motors


Process performance motors

Applications

§ VSD§ Typical

industries

Structure§ Main differences M3 – M4§ Frame, feet§ Lifting lugs§ Foot design§ Earthing terminals§ Rating plate

§ End shields

§ Drain holes

§ Terminal box

§ Fan, fan cover

§ Cooling

Lifecycle§ Efficiency

§ Bearings, sealings

§ Regreasing plate

§ Electrical design

§ Surface treatment

Support

§ Knowledge and expertise

§ Stock§ Options, variant codes§ Traceability§ Documentation§ After sales


Multiple Choice of Variants (Process Performance)


Process performance motorsDocumentation

§ Available from web sites in ABB standardformat

§ EC declarations of conformity§ Dimensional drawings§ 2D and 3D CAD drawings§ Connection diagrams (Basic)§ O & M Manual

§ Available on request:§ Data sheet§ Performance curves incl. torque-speed

curves§ Routine test certificates§ Environmental certificates§ Noise spectrums§ Type test reports§ Test together with frequency converters


High Efficiency Motors

§ 65 % of total electricity at industrial sitesis consumed by electric motors

§ Motor purchasing price corresponds to 8to 12 weeks of its electricity consumption

§ The capital cost will represent only 1% ofthe total life cycle operational costs of themotor

§ Reliable motors with a high efficiencylevel ensure the lowest life cycle costs


Energy Efficiency and Carbon Footprint ReductionEnergy facts about LV motors

Annual savings = 2.6 kW x 0.055 EUR* x 8760 hrs = 1251 EUR / 11 tonnes CO2 (0.5 kg/kwh)Annual savings = 2.6 kW x 0.07 USD* x 8760 hrs = 1594.32 EUR / 11 tonnes CO2 (0.5 kg/kwh)

Loss6.4 kWEfficiency = 92.1 %

Loss3.8 kWEfficiency = 95.1 %Reduced losses = 2.6 kW

81.4 kW

75 kW

If the efficiency level increases with 3 %-units, the reduction of losses is 40%

78.8 kW


* Sample tariff rate

New efficiency classes defined by IEC/EN 60034-30

Super premium efficiency * IE4 Super premium efficiency

Premium efficiency IE3 PremiumHigh efficiency IE2 Comparable to EFF1Standard efficiency IE1 Comparable to EFF2

*) IE4 level for asynchronous and synchronous motors defined byIEC 60034-31: 2010 Technical specification


Timeline for the EU MEPS

Phase 1:

From 16 June,2011

Motors with specification below mustmeet the IE2 efficiency level:-

0.75kW-375kW, 2-6 poles, up to 1kV50Hz

Phase 2:

From 1 January,2015

Motors with a rated output of 7.5 – 375kW must meet EITHER the IE3efficiency level OR the IE2 level if fittedwith a variable speed drive

Phase 3:

From 1 January,2017

Motors with a rated output 0.75 – 375kW must meet EITHER the IE3efficiency level OR the IE2 level if fittedwith a variable speed drive

Note!IE classes requiredby the regulationcorrespond to IEclass defined inIEC/EN 60034-30standard


Process performance cast iron motorsStructure - Rating plate, more examples for different motor sizes

Motor sizes 71-90

Motor sizes 160-250Motor sizes 100-132


BU Motors and GeneratorsLV Motor Manufacturing and Central Stock Locations

Central stocks

Manufacturing

Västerås,Sweden

Västerås, SwedenCentral Stock North

Menden, GermanyCentral Stock Europe

Barcelona, SpainCentral Stock South

Vaasa,Finland

Lodz,Poland

Faridabad&

Bangalore,India

Shanghai,China

Shanghai,Central Stock North

Asia

Singapore,Central Stock South

Asia


Some Customer Segments

Food & Beverage

Chemical &Petrochemical Water & waste water

Oil & Gas

Metals & mining

Pulp & paper

Steel Cranes & Marine Rail§© ABB BU Motors and GeneratorsMay 26, 2015 | Slide 74

Chiam Chee Seong27 May 2015

BU Motors & GeneratorsHazardous Area Information &Motor Portfolio

Group I

Explosive atmospheres are classified into groups:

Industries likechemical plants,petrochemical,industries orproducts storage,…

Group II

dust

gas

gas Mines full offiredamp were thefirst plants at risk

Group III

Hazardous Area MotorsExplosive atmosphere - Classification


Presence justin case of failure orabnormal operations

Continuouspresence

Presence duringnormal operations

n According to European Directives 94/9/EC (ATEX), IEC 60079-10, EN 60079-10 and NEC 505,explosive atmospheres are classified, relating to the presence probability of flammablesubstances, in ZONES:

n Zone “0”( Gas presence > 1000 hours/year)n Area where an explosive gas mixture is

present continuously, for long period orfrequently (Zone “20” for dust)

n Zone “1”( Gas presence 10 - 1000 hours/year)n Area where an explosive gas mixture is

likely to occur under normal operations(Zone “21” for dust)

n Zone “2”( Gas presence < 10 hours/year)n Area where an explosive gas mixture is

unlikely to occur (or occur only underabnormal conditions) (Zone “22” for dust)

Hazardous Area MotorsExplosive atmosphere – Group II


§Zone 2

§Zone 1

§Example: Tanker lorry loading units

Hazardous Area MotorsArea Classification


Based on these values the appropriate temperature classwill be determined for an equipment installed safely in thearea containing a combustible substance which does notexceed the auto-ignition temperature of the substance. Thistemperature class is mostly not exceeding 80% of the AIT,and in many industries may be even lower to provide abigger safety margin.

Classification of gases and vapoursin explosion groups and temperature classes

T1 T2 T3 T4 T5 T6

I Methane -

IIA AcetoneEthaneEthylacetateAmmoniaBenzolAcetic AcidCarbon monoxideMethanolPropaneToluene

EthylalcoholI-amyl acetateN-buthaneN-btylalcohol

PetrolDiesel fuelAviation fuelHeathing oilN-hexane

Acetaldehyde -

IIB Town gas(lamp gas)

Ethylen -

IIC Hydrogen Acethylene - Carbondisulphide

Comparison between Division and Class Grouping

Typical Gas Diivision SystemNEC 505

Zone SystemEN & IEC

Acetylene Group A

Hydrogen Group B

Group IIC

Ethylene Group C Group IIB

Propane Group D Group IIA

Hazardous Area MotorsExplosive Atmospheres


Relationship Between Gas/Dust Subdivisionsand Equipment Groups

Location gas/dustsubdivision

Permitted equipment group

IIA IIA or IIB or IIC

IIB IIB or IIC

IIC IIC

IIIA IIIA or IIIB or IIIC

IIIB IIIB or IIIC

IIIC IIIC

© ABB BU Motors and Generators

May 26, 2015 | Slide 81

Hazardous Area MotorsIEC and EN Standards (Former Edition)

T1 T2 T3 T4 T5 T6

450C 300 C 200 C 135 C 100 C 85 C


May 26, 2015 | Slide 82

§ Apparatus groups§ Group I - mines susceptible to firedamp§ Group II - other places

§ Gas group (needed only for Ex d and Ex i)§ IIA (e.g. Propane)§ IIB (e.g. Ethylene)§ IIC (e.g. Acetylene and Hydrogen)

§ Determination of Zone (presence of explosiveatmosphere…)

§ Zone 0/20- continuously or for long periods or frequently

§ Zone 1/21- in normal operation occasionally

§ Zone 2/22- not in normal operation, but if it does occur,will persist for a short period only

§ Temperature classes

T1 T2 T3 T4 T5 T6

450C 300 C 200 C 135 C 100 C 85 C


May 26, 2015 | Slide 83

§ Apparatus groups§ Group I - mines susceptible to firedamp§ Group II – areas with gas§ Group III – areas with dusts

§ Gas group (needed now for all )§ IIA (e.g. Propane)§ IIB (e.g. Ethylene)§ IIC (e.g. Acetylene and Hydrogen)

§ Dust group (needed now for dust as well)§ IIIA (combustible flyings, eg. fibers)§ IIIB (non-conductive dust)§ IIIC (conductive dust)

§ Determination of Zones as before§ Temperature classes as before

Hazardous Area MotorsIEC and EN Standards (Newest Edition)

Hazardous Area MotorsEquipment Protection Levels (EPL)

EPL Definition

Ga (gas) Equipment having a ”very high” (a) level of protection, e.g. ”ia”

Gb (gas) Equipment having a ” high” (b) level of protection, e.g.”ib”, ”d”,”p”, ”e”,(”de”)

Gc (gas) Equipment having an ”enhanced ” (c) level of protection, e.g.”ic”,”nA”

Da (dust) Equipment having a ”very high” (a) level of protection, e.g. ”ta”

Db (dust) Equipment having a ” high” (b) level of protection, e.g. ”tb”

Dc (dust) Equipment having an ”enhanced” (c) level of protection, e.g. ”tc”


May 26, 2015 | Slide 84

Hazardous Area MotorsEquipment Protection Level (Cont’)

§ Traditional relationship ofEPLs to zones

§ No additional riskassessment done ornecessary if used accordingto table

EPL Zone

Ga 0

Gb 1

Gc 2

Da 20

Db 21

Dc 22


May 26, 2015 | Slide 85

MG

StandarsEN 60079-0IEC 60079–0

General Rules for all Ex Motors

EN 60079-2IEC 60079–2Pressurised

“p”

EN 60079-1IEC 60079–1Flame Proof

“d”

EN 60079-7IEC 60079–7

Increased Safety“e”

EN 60079-15IEC 60079–15Non Sparking

“n”

ZonesZONE 1 ZONE 2

Motor category (ATEX only)Category 2 Category 3

Hazardous Area MotorsATEX and IEC Standard


No spark innormal conditions(outside and inside)

No dangerous hotsurfaces in normalconditions (outside andinside)

n What does it mean Non Sparking enclosure ?n Parts which could ignite an explosive gas are manufactured in

such a way that to prevent ignition of flammable gas

Hazardous Area MotorsNon Sparking Motors (Ex nA)

ABB standard certified for ExnA IIC T3

No spark in normal/fault conditions(outside and inside)

No dangerous hotsurfaces in allconditions (outsideand inside)

n What does it mean Increased Safety enclosure?n Parts which could ignite an explosive gas are manufactured in

such a way that to prevent ignition of flammable gas

Hazardous Area MotorsIncreased Safety Motors (Ex e)

n What does it mean Flameproof enclosure ?n The enclosure is designed in such a way that an explosion inside

the motor will not cause any permanent deformation and willprevent the flame propagation outside

seals and labyrinths

strong housing(frame and shields)

No spark in normaland fault conditions(outside)

No dangerous hotsurfaces in allconditions (outside)

Hazardous Area MotorsFlameproof Motors (Ex d)

Inletinert gas

Outletinert gas

po

p > po

n What does it mean Pressurized enclosure ?n Parts which could ignite an explosive gas mixture are housed in

an enclosure which is flushed and pressurized by a protectivegas, e.g. clean air

No spark in normal andfaul conditions(outside)

No dangerous hotsurfaces in allconditions (outsideand inside)

Hazardous Area MotorsPressurized Motors (Ex p)

n What does it mean protection by enclosures?n The enclosure is designed in such a way that dust can not

penetrate inside enclosure (at all IP65 or harmful amount IP56).

seals and labyrinths

Enclosure IPclassification

No spark innormal conditionsZone 22 (outside)

No dangerous hotsurfaces in normalconditions Zone 22(outside)

Hazardous Area MotorsDust Ignition Proof Motors (Ex tD)


Hazardous Area MotorsCertification


§ Certifications used as global§ IEC certificate

§ IECEx Scheme certificate

§ ATEX certification

§ CSA certification

§ Typical national certifications§ GOST to Russia

§ Inmetro to Brazil

§ CNEx for China

§ KOSHA for Korea

§ CCE / DGFASLI for India

ENCSA/CECCode

NEMA /NEC

AS/NZS

JIS

MG

Hazardous Area MotorsCertification


ABB the first to use the IECEx conformity mark

§ ABB is the first motormanufacturer to be granteda licence to use the IECExconformity mark

§ Globally certified, withglobal support and certifiedservice

© ABB BU Motors andGenerators May 26, 2015 |Slide 94

0 100 1000 10000 100000

kWLV motorsHV Cast iron frame

HV Welded frameSynchronous

§ Flameproof Ex d/Ex deIEC 80-710, up to 4500 kW

§ Increased safety Ex eIEC 80-500, up to 1500 kW

§ Pressurized Ex px/Ex pxeIEC 355-2500, up to 60 MW

§ Non-sparking Ex nAIEC 71-2500, up to 60 MW

§ Class I Div 2/Zone 2up to 60 MW, 80000 HP

Hazardous Area MotorsPortfolio


Sizes 56-45056 63 71 80 90 100 112 132 160 180 200 225 250 280 315 355 400 450

Hazardous area motors56 63 71 80 90 100 112 132 160 180 200 225 250 280 315 355 400 450

Flameproof motors: M3JP (Ex-d); M3KP (Ex-de)

Increased safety motors: M3HP (Ex-e)

Non-sparking cast iron motors: M3GP (Ex-nA)

Dust ignition protection cast iron motors: M3GP (Ex-tD)

Hazardous Area MotorsProduct Portfolio (LV)

ABB LV motors for explosive atmospheres - PG IEC LV Motors (BU Motors and Generators)


Hazardous Area MotorsIEC/EN 60079-31 Protection by enclosure “t”

§ All general requirements about dust are in the new IEC/EN 60079-0

§ Specific requirements for Ex t motors are in the new standard IEC/EN60079-31

§ Gaskets and seals:

§ shall be made of one-piece continuous construction, i.e. with anuninterupted periphery

§ Dust group III divided into:

§ IIIA for combustible flyings

§ IIIB for non-conductive dust

§ IIIC for conductive dust


May 26, 2015 | Slide 97


May 26, 2015 | Slide 98

Hazardous Area MotorsIEC/EN 60079-31, terminal boxes Ex t

§ Terminal boxes for Ex t low voltage cast iron motors

§ Left image: uninterrupted gasket, permitted for new standard Ex t

§ Right image: interrupted gasket: not permitted !

§ Consequences:

§ New terminal box designed is required on some products

Hazardous Area MotorsNew marking (IEC) gas


May 26, 2015 | Slide 99

§ Ex - Explosion protected apparatus

§ de - Type of Protection “de”§ II – group for gas

§ B – gas group

§ Temperature class

§ New protection level marking for gas,§ b = high level of protection

Ex de II B T4 Gb

Hazardous Area MotorsNew marking (ATEX, EN) gas


May 26, 2015 | Slide 100

Ex de II B T4 GbEx - Explosion protected apparatus

Standard markingaccording to EN-standards

Type of ProtectionII - Group (gas)

A, B, C - Gas groups

Temperature class

Equipment protection level for gas

II 2 G0081

for GasEquipment category (Zone 1)

Equipment group for surface industryUse in explosive atmosphere

Notified body eg. 0081 - LCIECE-marking

Marking according to ATEX-directive

Hazardous Area MotorsNew marking (IEC) dust


May 26, 2015 | Slide 101

§ Ex - Explosion protected apparatus

§ tb - Type of Protection “tb”§ III – new group for dusts

§ C – new group for conductive dust

§ Temperature class

§ New protection level marking for dust,§ b = high level of protection

Ex tb III C T125ºC Db

Hazardous Area MotorsNew marking (ATEX, EN) dust


May 26, 2015 | Slide 102

Ex - Explosion protected apparatus

Ex tb III C T125°C DbStandard markingaccording to EN-standards

Type of Protection “t” for dust and protection level “b”III - Group (dust)

A, B, C - Dust groups

Temperature class

Equipment protection level for dust

II 2 D0537

for DustEquipment category (Zone 21)

Equipment group for surface industryUse in explosive atmosphere

Notified body eg. 0537 - VTTCE-marking

Marking according to ATEX-directive

© ABB BU Motors & Generators

Markings on rating plates in practiceBoth IECEx and EN (ATEX) markings included

§ Ex marking according to EPLgeneration of standards

§ Markings according to both IEC andEN (ATEX) standards for fullflexibility

§ Ga = Equipment for explosiveatmospheres having a ‘very high’level of protection

§ Gb = Equipment for explosiveatmospheres having a ‘high’ level ofprotection

§ Gc = Equipment for explosiveatmospheres having an ‘enhanced’level of protection

§5/26/2015 §| Slide 103

§ ABB’s Ex motors are tested and ATEXcertified for safe use with converters!

§ Safe combinations are available for severaldifferent applications.

§ Contact ABB for best solution

Hazardous Area MotorsATEX Certified Ex Motors for VSD Applications


Ex Motors’ Loadability Curves for ABB Frequency Converters withDTC Control (Zone 1 & Zone 2)


Ex Motors’ Loadability Curves for ABB ACS550 (Zone 1) and Non-ABB Voltage Source PWM-type Converters at (Zone 2)


Ex Motors’ Loadability Curves for ABB ACS550 for Zone 2


§ 450 km from Helsinki

§ Visiting address:

§ Strömbergin Puistotie 5 A,FI-65320 Vaasa

§ Factory area 34.000 m2

§ Focus and R&D responsibility:

§ Motors for frame sizes 80-132 &280 to 450, both in cast iron.

§ Hazardous area motors for framesizes 71 to 450

Hazardous Area MotorsManufacturing (FIMOT – Vaasa, Finland)


© ABB| Slide 110


May 26, 2015












PG Large AC MotorsTechnical and Product Presentation

Koh Joon Huan, 27th May 2015


Standards

International standards:

Regional standards:

National standards:

IEC(International Electro technicalCommission)IEC 60034-XXX

CENELEC(European Committee forElectro technical Standardization)EN XXX

NEMA(National ElectricalManufacturersAssociation)

AMN(MERCOSURStandardizationAssociation)

IEEE

VDEGermany

ISIndia

SENSweden

DINGermany

BSGreat Britain


StandardsABB strongly supports the drive to harmonise European standards and activelycontributes to various working groups within both IEC and CENELEC.

IEC defines:

Electrical:§ IEC 60034-1: Rating and performance

§ IEC 60034-2-1: Methods for determining losses and efficiency of rotatingelectrical machinery from tests *NEW!*

§ IEC 60034-8: Terminal markings and direction of rotation of rotating machines

§ IEC 60034-12: Starting performance of single-speed three-phase cageinduction motors for voltages up to and including 660V

§ Concerning non-hazardous area motors EN standards basically follow IEC standards.The biggest differences can be found with parts for hazardous area motors.


StandardsMechanical:§ IEC 60072-1: Dimensions and output series for rotating electrical machines - Part1: Frame

numbers 56 to 400 and flange numbers 55 to 1080

§ IEC 60072-2: Dimensions and output series for rotating electrical machines - Part2: Framenumbers 355 to 1000 and flange numbers 1180 to 2360

§ IEC 60034-5: Degrees of protection provided by the integral design of rotating electricalmachines (IP code) – Classifications

§ IEC 60034-6: Methods of cooling

§ IEC 60034-7: Classification of types of construction, mounting arrangements and terminalbox position (IM code)

§ IEC 60034-9: Noise limits

§ IEC 60034-14: Mechanical vibration of certain machines with shaft heights 56mm andhigher - Measurement, evaluation and limits of vibration


Hotspot temperature marginMax. temperature riseMax. ambient temperature0

20406080

100120140160180

B F H

Deg

.C

40 40 40

80

1010

105125

15

130155

180

Insulation classes acc. to IEC 85Insulation class Maximum winding temperature

• Motor with temp rise B is common requirement, with insulation temp rise F, [VacuumPressure Impregnated (VPI), Micadur® Compact resin.]

• 2 method to use, resistance or ETD.

• A good winding should have temp rise close to even.

• ABB standard using resistance method.

• Motor can be tested with ETD upon request.


Conditions

Ambient temperature, ºC 30 40 45 50 55 60 70 80Permitted output,% of rated output 107 100 96,5 93 90 86,5 79 70

Height above sea level, m 1000 1500 2000 2500 3000 3500 4000

Permitted output,% of rated output 100 96 92 88 84 80 76

§ Standard ambient temperature: -20°C to +40°C

§ Standard altitude: 1000 m above sea level


Permissible temperature rise of marine motors

Classification Ambient Permissible temperaturesocieties and rise K for stator windingsstandards temperature Insulation class

°C B F

IEC Publ. 60034-1 40 80 105

IEC 92-301 50 70 90

ABS 50 70 95

BV 45 75 100

CCS 45 75 100

CR 45 75 95

DNV 45 75 100

GL 45 75 100

KR 50 70 90

LR 45 70 95

NK 45 75 100

RINA 45 75 95

RS 45 75 95


Type Tolerance Note

±

Min.0,02/Max.0,07

Voltage deviation 5% Continuous± 10% (+10K) Short time

Power factor -1/6 of (1-cosj)

Efficiency -15% of (1- h) P2 < 150 kW-10% of (1- h) P2 > 150 kW

Speed ± 20% of guaranteed slip

Overspeed 120% for 2 min.

Start torque -15 to + 25%

Maximum torque -10% Min. 160% of Tn

Pull-up torque -15 %

Locked rotor current (start current) +20%

Nominal tolerancesElectric tolerances acc. to IEC 60034-1


Index of Protection (IP) ClassesIEC 60034-5

Sometimes a third digitis used for instanceIP557 The third digitmeans shock test inJoules (ex. 7= 7Joules)

IP W23 (W= “Weatherprotected” ->Customer informationto the manufacturerrequired)

§© ABB BU Motors and Generators November 4, 2010 | Slide

Basic IEC StandardIEC 60034-6 IC Code



May 26, 2015 | Slide 121

• Rib cooled motors

• IC411 is most common for lower powermotor, heat dissipate from stator to fin, fincool down by cooling air.

• Simple cooling method, easy to installand less maintenance.

• With increase frame size, distance ofmotor center with fin become larger,cooling efficient reduce.

• More cooling method with higher power.

• Modular motor, cooler can be changeeasily, allow for different coolingrequirement.

• Cooling requirement usually depend oninstallation location, for a balancedbetween commercial and technical



§ IC 81W § IC 611 § IC 01


Examples of common mounting arrangementsCode I IM B3 IM V5 IM V6 IM B6 IM B7 IM B8Code II IM 1001 IM 1011 IM 1031 IM 1051 IM 1061 IM 1071

Foot-motor:

Code I IM B5 IM V1 IM V3 *) *) *)Code II IM 3001 IM 3011 IM 3031 IM 3051 IM 3061 IM 3071

Flange-mounted motor,large flange withclearance fixing holes.

Code I IM B14 IM V18 IM V19 *) *) *)Code II IM 3601 IM 3611 IM 3631 IM 3651 IM 3661 IM 3671

Flange-mounted motor,small flange withtapped fixing holes.

International Standards;IM Mounting Arrangements IEC 60034-7


Designation forInternational mountingType of construction, foot-mountedmotor with two bearing end shieldsMounting arrangement, horizontalmounting with feet downwards etc.External shaft extension, onecylindrical shaft extension etc.

IM 1 00 1

Example of designations acc. to Code II

IEC 34-7 specifies two ways of stating how a motor is mounted.§ Code I covers only motors with bearing end shields and one shaft extension.§ Code II is a general code.

- Mounting arrangement is very important to manufacturer as there might have somespecial consideration required especially for vertical mounted motors (eg: V3, V6,V1….)

- Special end shield or seals is required for those shaft upwards where water/liquid areexpected to go down along the shaft.

International StandardsIM Mounting ArrangementsIEC 60034- 7


Acc. to Cenelec Harmonization Document (HD 231)

Motor Dimensions and PowersIEC 60034-7


§ ABB’s motors have a low noise level

§ Average test values are presented in respective productcatalogues

§ Guaranteed noise data can be supplied on request

§ Noise level is given as mean sound pressure level at full load and1 m distance

NoiseIEC 60034-9


Limits of maximum vibration magnitude in displacement, velocity and acceleration (r.m.s.) for shaft height H

Grade ”A” applies to machines with no special vibration requirements.

Grade ”B” applies to machines with special vibration requirements. Rigid mounting is not considered acceptable formachines with shaft heights less than 132 mm.

The interface frequencies for displacement/velocity and velocity/acceleration are 10 Hz and 250 Hz respectively.

•Vibration affect coupling and foundation design

•Large AC motor had to be install at rigid mounting

•Most coupling can take grade A vibration easily.

•Standard ABB Large AC motor grade A vibration, grade B is an option.

VibrationIEC 60034-14

Grade A is thestandard gradeused by ABB

• During starting, rotor is in 0 speed.

• High starting current drawn by motor, high magnetic flux generated.

• Additional stress on insulation, aging on insulation.

• ABB standard design life time 20 years with 1000 start per year

§© ABB BU Motors and Generators May 26, 2015 | Slide 128

Basic IEC StandardStarting And Re-Starting

• High starting current drawn by motor during starting

• Network voltage will reduce depend on short circuit capacity

• With lower voltage, lower torque generated, motor maybe unable to start

• Common industry requirement is motor had to start at 80% Un

• Load curve is needed to confirm motor starting

• ABB standard, motor torque need to be at least 10~15% higher than load torque


Basic IEC StandardStarting and Re-Starting

• 3/2 start or 2/1 start is often

required.

• Cold start -> motor at

ambient temp

• Hot start -> motor at

operating temp

• Higher inertia lead to longer

starting time, higher motor

temperature

• With load curve and inertia,

3/2 or 2/1 start can be

confirm.


Basic IEC StandardStarting and Re-Starting

MG

StandarsEN 60079-0IEC 60079–0

General Rules for all Ex Motors

EN 60079-2IEC 60079–2Pressurised

“p”

EN 60079-1IEC 60079–1Flame Proof

“d”

EN 60079-7IEC 60079–7

Increased Safety“e”

EN 60079-15IEC 60079–15Non Sparking

“n”

ZonesZONE 1 ZONE 2

Motor category (ATEX only)Category 2 Category 3


Basic IEC StandardIEC 60079 Explosive atmospheres

§ Cast iron motors

§ Modular induction motors

§ Flameproof motors

§ Slip-ring motors

§ Synchronous motors

§ Permanent magnet motors

§ LV induction motors usingform wound coils

PG Large AC MotorsProduct portfolio


PG Large AC Motor product offeringHV induction and synchronous motors

§ HV induction motors

§ Synchronous motors

Output power

140 kW – 23 MW

1– 65 MW


Process performance motor

§ Standard high voltage motor

§ Based on proven platform

§ For serial OEM’s with short delivery time§ Power: 110 – 750 kW

Frame sizes: 315 – 450

PG Large AC Motor product offeringRib cooled motors


Engineered rib cooled motor NXR§ Power 100 – 900 kW§ Frame sizes: 355 to 400§ New platform for HV rib cooled motors§ High efficiency levels, low noise levels§ Fixed speed and safe area use

Engineered rib cooled motor HXR§ Power 100 – 2,250 kW§ Frame sizes: 355 to 560§ High efficiency levels, low noise levels§ Fixed speed, variable speed and

hazardous are use

PG Large AC Motor product offeringRib cooled motors


§ Built from the basic design by using modular construction

§ Complete range of enclosures and cooling arrangements

§ Optimal weight to power ratio

§ Power: 140 – 23,000 kWFrame sizes: 400 – 1000

§ Optimized electrical design

§ Vacuum pressure impregnated stator winding

§ Reliable and rugged heavy-duty construction

§ Low vibration and noise levels

§ Fit for frequency converter supply

§ Designed for tough ambient conditions

§ Easy installation and maintenance

§ Wide range of accessories

§ Wide range of applications including compressors, pumps,fans, blowers, conveyors, mills, crushers, refiners and shipthrusters

PG Large AC Motor product offeringModular induction motors


§ Motor intended for explosiveatmosphere§ Protection category acc. to EN/IEC

Flameproof Ex d, Ex de

§ Totally enclosed, fan cooled

§ Cooling methods: IC411 and IC511

§ Both cast iron and welded steel frameavailable

§ Certified according to ATEX Directives,IEC, EN and NEMA standards and allmajor local requirements

§ Suitable for variable speed drives


PG Large AC Motor product offeringFlameproof motors Ex d


§ Slip ring unit located separately at theend of the motor to allow easymaintenance

§ Can be equipped with permanentcontact brushes

§ Suitable for variable speed drives orwith a brush lifting device for continuousrunning


PG Large AC Motor product offeringSlip-ring motors


§ ABB synchronous motor modular productplatforms cover:§ From small to large power:

1 - 65 MW1 300 - 87 000 HP

§ From slow to full speed: 20 - 2000 rpm (also2 pole available)

§ From small to large size:Shaft height 0710 - 2500 mm

§ From medium to very high voltages:1 - 60 kV

§ Endshield and pedestal mounted, horizontaland vertical design

§ All main cooling types§ Motor design for hazardous environment

according to main Ex standards§ All main DOL starting methods and VSD

technology supported

PG Large AC Motor product offeringSynchronous motors


§ Motorformer (Very High Voltage motors)with a new stator technology, based onpatented and well-known high voltagecable winding concept

§ Lower operating costs and increasedutilization of reactive power due toeliminating the power transformersystem

§ Fewer components for savings inservicing, maintenance and spare parts

§ Complete range of enclosures andcooling arrangements

§ Low weight to power ratio

PG Large AC Motor product offeringMotorformer


© ABB| Slide 142


May 26, 2015











© ABBSlide 143May 26, 2015

Drives, PLC and automation productsfor all needs

BU Drives and Controls, January 2015


Low voltage AC and DC drives§ Micro drives 0.18 to 4 kW

§ Machinery drives 0.18 to 560 kW

§ General purpose drives 0.75 to 355 kW

§ Motion control products 1 to 33 kW

§ Industrial drives

§ Low voltage AC 0.55 to 5600 kW

§ Low voltage DC 7.5 kW to 4.8 MW

§ Industrial specific drives 0.37 to 400 kW

§ Drives for HVAC

§ Drives for water

ABB BU Drives and ControlsProducts

Medium voltage AC drives§ General purpose drives 0.25 to 7 MW

§ Special purpose drives 2 to 100 MW

PLC and Automation products§ AC500-eCo, AC500§ AC500-S, AC500-XC§ S500 Remote I/O§ CP600 HMI


BU Drives and ControlsMarkets served

HVAC

Marine

Water and waste waterFood industry Beverage industry

Pulp & Paper Metals industry Mining

Power generation Cement Chemicals Oil upstream

Material handlingTextile MotionPlastics


Low voltage AC drivesProducts


§ From 200 to 480 V

§ For pumps, fans, and constant torque applications

§ IP21 and IP54 enclosures

§ Vector control

§ Assistant control panel

§ EMC filter (C2)

§ Modbus RS-485

§ Swinging choke for superior harmonic reduction

§ Options§ Basic control panel§ Fieldbus adapters, panel mounting kits, relay

output extension module§ Output chokes§ Brake units and choppers§ FlashDrop tool

ABB general purpose drivesACS550, 0.75 to 355 kW


ABB machinery drivesACS850-04, 1.1 to 500 kW

§ From 380 to 500 V

§ IP20

§ Fast, cost effective cabinet installation andintegration

§ Compact size and side-by-side mounting

§ Wide range of options and extensive standardinputs and outputs

§ Safe Torque Off (STO)

§ Removable memory unit

§ Drive-to-drive link for master-follower application

§ Energy optimizer and energy saving calculator

§ Options§ Control panel

§ Crane control software

§ Various power and IO options


ABB industrial drivesACS880 series 0.55 to 5600 kW

ACS880 drive modules

ACS880 multidriveACS880 single drives


Single drivesACS880 0.55 to 3200 kW

• Wall-mounted drives, ACS880-01

• Cabinet-built drives, ACS880-07

• Voltage range from 208 to 690 V

• Built on ABB´s all-compatible drives architecture:• Intuitive control panel and PC tool• Enhanced direct torque control (DTC) for

precise open and closed loop control• Built-in safety features• Communication with all major automation

networks• Removable memory unit for easy drive

commissioning and replacement• Energy optimizer and energy efficiency

information• Application control programs and drive

application programming with IEC 61131-3programming


Drive modulesACS880 0.55 to 3200 kW

• Designed for system integrators and OEM’s whointegrate drive modules into their own systems orsubsystems.

• Built on ABB´s all-compatible drives architecture• Air-cooled multidrive modules:

• Inverter modules, 380 to 690 V• IGBT supply modules, 150 to 630 kVA• Diode supply modules (DSU), 55 to 5445 kVA• Brake choppers and resistors

• Air-cooled single drive modules:• ACS880-04, IP20• ACS880-01, IP20 +P940

• LV AC drive modules engineering support -site


MultidrivesACS880 1.5 to 5600 kW

• Voltage range from 380 to 690 V• Built on ABB´s all-compatible drives architecture• Air-cooled multidrives with:

• Inverter units, 380 to 690 V• IGBT supply units, 380 to 500 V• Diode supply units (DSU), 55 to 5500 kVA

• Common DC busbar with single power lineconnection

• Compact design for easy cabinet assembly andmaintenance

• Fast connectors for motor cables in the bottompart of the cabinet

• Shared energy and motor-to-motor brakingwithout braking chopper or regenerative supplyunit

• Common braking resourced to several drives


ABB industry-specific drives for HVACACH550, 0.75 to 355 kW

§ From 208 to 480 V

§ Full motor current up to 50°C

§ IP21 or IP54

§ Assistant control panel

§ Specific application macros

§ Embedded BACnet, Modbus, N2 and FLNprotocols

§ Swinging choke for superior harmonicreduction

§ EMC filter (C2)

§ Options§ Fieldbus adapters, panel mounting kits, relay

output extension module

§ Output chokes

§ FlashDrop


ABB industry-specific drives for water and wastewaterACQ810-04 , 1.1 to 400 kW

§ Từ 380 đến 480 V§ IP20§ Tailor-made pump control functions for single

and multi-pump systems§ Assistants for pump system start-up,

maintenance and diagnostics

§ Energy optimizer and energy efficiencycalculator

§ Side-by-side mounting§ Coated boards§ Options

§ I/O extensions

§ Fieldbus adapter modules

§ Harmonics filters

§ EMC (C2) filters


ABB application control programs

§ Centrifuge and decanter control program for effective separation of solidsfrom liquids and co-ordinated speed difference control

§ Crane control program§ Master/follower control program for load sharing between mechanically

connected motors

§ Multiblock control program for versatile adaptive programming

§ Motion control program for positioning and synchronising in machineryapplications

§ PMSM control program Permanent magnet motor control for high torque andlow-speed applications

§ Pump control program§ Rod pump control program and PCP/ESP pump control program for the oil

industry

§ Spinning and traverse control programs for high-quality yarn production

§ Winch control program for mooring and anchor handling

§ Winder control program for precise tension


PC tools, remote monitoringoptions and fieldbusadapters


Drive PC tools

Engineering tools§ DriveSize and MCSize - dimensioning drives andmotors

Integration tools§ DriveOPC – Integrating ACS800 with OPC

Programming tools§ DriveSPC - programming of ACSM1, ACS850§ DriveAP - adaptive programming of ACS800

Start-up and maintenance tools§ Drive composer – All-compatible drives portfolio

including ACS880, ACS580 drives§ DriveStudio – ACSM1, ACS850 drives§ DriveWindow - ACS800 drives§ DriveAnalyzer – ACS800 drives§ DriveWindow Light – standard drives§ DrivePM – creating FlashDrop parameter sets§ DriveConfig kit – for ACS55§ DriveBrowser - fieldbus based tool connected to

Ethernet network


Drive PC toolsTools for calculating energy savings

§ FanSavefor comparing energy consumptionbetween different fan control methods

§ PumpSavefor comparing energy consumptionbetween different pump control methods


Remote monitoring toolsSREA-01, Ethernet adapter

Main features§ Remote monitoring using a web browser§ Remote access to drive parameters§ Local trending, send logs by e-mail§ Alarming by e-mail and SMS

Connectivity§ Local Ethernet (Internet connectivity via external firewall)§ EIA-232 for GSM, GPRS, 3G or analog modem§ EIA-232, EIA-485 or Ethernet for drive connection§ Connection to the drive by Modbus (panel port, embedded Modbus or a

Modbus adapter)§ Possibility to connect up to 10 drives

Drive compatibility§ ACS310, ACS355, ACS550, ACH550, ACQ810, ACS850, ACSM1§ Limited to ACS800-01 (standard control program)


Remote monitoring toolsNETA-01, Ethernet adapter

Main features§ Remote monitoring using a web browser§ Remote access to drive parameters§ E-mail alarms and reports§ Modbus/TCP for monitoring and control

§ Response time ~100 ms

Connectivity§ Local network (Ethernet)§ DDCS for drive connection§ Possibility to connect up to 9 drives

Drive compatibility§ ACS800 (with DDCS option modules)

© ABB| Slide 162


May 26, 2015











© ABB BU LV MotorsMay 26, 2015 | Slide 163

BU Motors & GeneratorsDimensioning Tool MotSize/ DriveSize

Chee-Seong Chiam27th May 2015


Background

§ Approximately 12 different tools for AC drive dimensioning

§ Requirement for a user friendly and reliable tool

§ Standardize the rules for dimensioning and insure thatresults were accurate

§ Software based on the Windows environment

RoseRose

ACDDIMACDDIM

SoftsizeSoftsize CraneDIMCraneDIM

RollDIMRollDIM

Harmon16Harmon16

Etc.Etc.

PC-CatPC-Cat

OneDimensioning

Tool


Program

Rose

ProjectDatabase

DriveSize

Product SpecificDimensioning Rules

User interface- Project Information- Selected Units

Product Databases

ACS 550

Trafo

ACS 1000

MotSizeDirect On Line

Motors

ACS 1000Catalogue

MotorCatalogue

ACS 800Catalogue

TrafoCatalogue

ACS 550Catalogue

ACS 800

MotSize

Safe areamotors

Hazardousarea

motors


Available Motor Types in Program

Standard Motors

§ Aluminum

§ Cast Iron

§ Break motors

Marine Motors§ Aluminum§ Cast Iron

Ex Motors1. Aluminium

- ExnA

2. Cast Iron- ExnA- Exd/de- Exe- DIP/ExtD


General Program Features

§ Ambient temperature

§ Altitude

§ Supply network data

§ Load type and duty cycle

§ Motor temperature rise

§ Both imperial and metric units

§ Results in numerical and graphical form

§ Print outs


MotSize Main Screen Parameters

Up to 55°C, EEx 50 °C, EEx e40 °C60°C – 80°C : for information

Not specifiedYD

Select list of motorsAccording to catalogue

S1 : Continue dutyS2 : 10’ - 30 ‘ - 60’S3 / S6 : 15%-25%-40%-60%S4 : Int. duty : cycle/h

GeneralPerformanceProcessPerformanceMarine motorsHazardousAreas

List according to Motor type :M2AA-M2BA-M3AA-M3BP-M3JP - M3KP etc.EEx n T3 – EEx e – EEx d / de

Up to 4000 m

StandardBrake

What everB for 80KF for 105 K

Load type

Powerrestamping

AluminiumCast iron

BasicHigh-output


Selection Modes

There are 4 different way of choosing a motor:

1. Guided selection

2. Advanced selection

3. Catalogue guided selection

4. Catalogue advanced selection


Starting MotSize (For Direct On Line Start Motors)

Double click on“MotSize” shortcut iconin desktop or WindowsProgram list

MotSizelaunchingscreen


Starting MotSize

Fill in the motor range and project information.


Supply Ratings

Select voltage frequency


Guided SelectionExample: Choosing an IE2,16kW, 4-pole, cast iron Process Performance motor

To start dimensioningyou have to click one ofthese iconsOr press Ctrl+DOr press Tools, makedimensions


Guided Selection

§ Guided selection shows all available standard motors160 kW 4-poles.

§ Now you can select the type you want


Advanced Selection

This is like guided selection BUT you have to select motor type and family


Catalogue Guided Selection

You can limit your selection by choosing just a certain poweror the whole catalogue range


Catalogue Guided Selection

Table shows all motors selectable from catalogue between 11- 20 kW ->You have to pick the ones you need


Catalogue Advanced SelectionThis is like guided selection BUT you have to select motor type, family and power range.


Catalogue Advanced Selection


§ Kindly advise a DOL motor that meet requirements below:-

§ IE2 aluminium M3AA frame size 200 motor

§ Power 30 kW, 415VD, 50Hz, 2-pole, IM B35

§ Ambient temperature 50°C, altitude 1000m

§ Aluminium frame, IP 56, according to IEC

§ Temperature Class B

§ Restamp the motor to 27 kW

§ Inform the Efficiency level and Power Factor at 100% ,75% and 50% of load

§ Generate the datasheet in Finnish language

Exercise 1


Starting MotSize (For Direct On Line Start Motors)

Double click on“MotSize” shortcut iconin desktop or WindowsProgram list

MotSizelaunchingscreen


Exercise 1. Project Information


Exercise 1. Main Screen – Network data

Choose network:Voltage 415V andFrequency 50Hz


Exercise 1. Motor Selection

Choose:RangeTemperature risePolesLoadIP classMounting

To start dimensioningyou have to click one ofthese iconsOr press Ctrl+DOr press Tools, makedimensions


Exercise 1. Motor Selection

Choose the motoryou want


Exercise 1. Restamp the motor

Restamping can be done by entering new power here or by selecting the “Run button”


Exercise 1. Running Performance


Click on the buttom Results to see the values of Efficiency level andPower Factor at 100% , 75% and 50% of load.

Exercise 1. Results


Exercise 1: Datasheet


Exercise 2

§ Kindly advise a DOL motor that meet requirements below:-

§ IE2 cast iron motor

§ Group II, Zone 1, IIC, T4

§ Power 90 kW, 380VD, 50Hz, 4-pole, IM V1


§ Aluminium frame, IP 56, according to IEC


§ Restamp the motor to 85 kW

§ Inform the Efficiency level and Power Factor at 100% ,75% and 50% of load

§ Generate the datasheet in English language


Exercise 2. Project Information

Exercise 2. Results



§ Select the right motor:

§ Cast Iron

§ Power 160 kW, 690V, 50Hz,IM B5

§ Load type constant torque and constant power

§ Speed range 500-1000-1500rpm

§ Overload 120% for 25s at every 600s


§ IP 55, according to IEC


§ Cooling IC416

Exercise 3


Exercise 3: Starting DriveSize (For VSD Start Motors)

Double click on“DriveSize” shortcuticon in desktop orWindows Program list

DriveSizelaunchingscreen


Exercise 3: DriveSize Main Screen Parameters

Networksupply, type ofdrive andmotorselections

Load type:constant torque/constant power/constant torqueand power

Overload type:Simple cyclic/multiform cyclic/one time at start

To be filled up:Speed range/power/ overloadand period

Choose:Motor type/Temperature riseIP classMounting


Exercise 3: Key in the voltage and frequency

First, select thenetwork supplypage

Next, input thevoltage andfrequency


Exercise 3: VSD Motor Selection

§ Press “CTR+A” once all the data have been inputted.

Select themotor selectionpage

Input all thedata in thecolumns


Exercise 3: Selected Motor

Drive selected: ACS800-02-0260-7Motor selected: M3BP355SMB6


ABB and BaldorIntegration

ABB acquired Baldor Electric Company, a North Americanleader in premium efficient industrial electric motors andmechanical power transmission products on January 27,2011

This combination creates the world’s largest provider ofindustrial electric motors

This combination provides ABB with a market leading familyof enclosed gearing, mounted bearings and powertransmission components


About Baldor

Baldor Electric Company was founded in 1920 “tobuild a better motor”

Only industrial products (no residential or automotive)Leading customer preference in North America for

industrial electric motors with Baldor*Reliancebrand

Market leading line of mechanical power transmissionproduct with Dodge brand

Very broad and diverse customer basemore than 175 end marketsmore than 10,000 customers worldwide

Award-winning, union-free manufacturing facilitiesAcquired Reliance and Dodge brands in 2007,

doubling the size of the company7,000 + employees globallyProducts sold in over 70 countries


About BaldorRegion Sales Support and Application Engineering

Baldor US Team

Baldor teamAlrode, South Africa

Baldor teamShanghai, China

Baldor teamPune, India

Baldor teamCologne, Germany

Baldor teamSantiago, Chile Baldor team

Singapore

Baldor teamSeven Hills, Australia

Baldor teamDubai, UAE

Baldor teamMilan, Italy

Baldor teamBristol, England

Baldor teamVasteras, Sweden


Dodge mechanical productscomplement motors and drives

§ Motors, drives and mechanical power transmissionproducts can be used together in many applications

Drives

InboundPower

MotorsMechanical PowerTransmissionProducts

Motion drivenequipment


ExampleABB offering for Air Handling

ABB Drives ABB IEC Motors Dodge Couplings Dodge MountedBearing Units

+ + +or

Baldor*RelianceNEMA Motors

Grid-Lign Coupling 6,000 + kWat 1450 RPM

Gear Coupling 18,000 kW at1450 RPM

SleevoilHydrodynamicBearing Up to 14”/ 350 mm

HFOOil LubricatedSpherical Bearing75 – 240 mm

ISNGreaseLubricatedSpherical Bearing30 – 140 mm

SCGreaseLubricated BallBearing 17 – 85mm


NEMA and MPTProduct portfolio BU M&G

Baldor•Reliance NEMA MotorsDodge Mechanical PowerTransmission Products


NEMA motor family from Baldor

AC Motors§ More than 175 end markets§ Super-E premium efficient family§ Single phase§ Specialty§ Adjustable speed§ Above NEMA frame

DC Motors§ More than 175 end markets§ Fractional HP PM and Wound Field§ Round Body§ Laminated Frame


MPT products from Baldor

Mounted bearings

Enclosed gearing

Couplings

Sheaves

Bushings


Dodge enclosed gearing products

Torque-Arm and TAII Shaft Mount Quantis Helical and Bevel-helical Gearmotors

MagnaGear XTR Motorized Torque Arm Controlled Start Transmission (CST)


Dodge mounted bearings

Mounted Ball Bearings12 mm to 85 mm bore (½” to 3 ½”)Additional secondary subjectPillow block, flange units and take-upsSet screw, clamp collar, adapter and eccentric mountCast iron, polymer and stainless steelAll industries

Mounted Roller Bearings30 mm to 400 mm bore (1 ⅛” to 15 ¾”)Mounted tapered and mounted spherical rollerPillow block, flange units and take-upsSet screw, adapter and direct mountMining, aggregate & cement, air handling and powergeneration

Mounted Plain (or Sleeve) Bearings80 mm to 350 mm (1-7/16” to 14”)Oil film hydrodynamic bearingAir, water and oil cooledHigh speeds, hot shaftsIndustrial fans used in power generation, petroleum


Dodge couplingsElastomeric and metallic coupling families


Dodge couplingsElastomeric couplings

Para-Flex D-Flex Poly-Disc

Para-Flex Couplingsemploy a molded, non-lubricated elastomericflexing member loaded inshear; ATEX certified

D-Flex Couplings employ amolded, non-lubricatedelastomeric flexing sleeveloaded in shear; ATEXcertified

Poly-Disc Couplings are a pintype coupling using a moldedpolyurethane disc

Industry - Steel, Copper, Paper,Petro-chemical, Food, WW,Transportation

Applications – Pumps;Compressors; Fans;Conveyors, motors, engines,and turbines






Dodge couplingsMetallic couplings

Grid-Lign Gear

Tapered grid styleHubs, grids, andcovers

Power dense andcapable of transmittinghigh torque at highspeeds while stillremaining inherentlywell balanced

Industry - Steel, Copper,Paper, Petro-chemical, Food, WW,Transportation

Applications – Pumps;Compressors; Fans;Conveyors, motors,engines, and turbines

Industry - Steel, Copper,Paper, Petro-chemical, Food, WW,Transportation

Applications – Pumps;Compressors; Fans;Conveyors, motors,engines, and turbines

New Disc Coupling

Industry leading torqueand misalignmentcapabilities for longer lifeand improved reliability.Non-lubricated disc designincreases productivity.

Industry – Chemical, Oil,and Gas; Pulp &Paper.

Applications – Pumps;Compressors; Fans;motors, engines, andturbines


Dodge PT ComponentsMechanical drive components

Sheaves and Bushings§ V-Belt & High Torque Synchronous Belt

Drives-HTR and HTRC§ Taper-lock or QD bushing availability§ Industries-Air and Material Handling


Unit/Bag Handling Air Handling

PharmaceuticalFood/Beverage

PowerGen

Petroleum Chemical

Water/Waste Water

Key industries for mechanical power transmissionMining

Forest Products

Cement

Pulp & Paper

Aggregate

Metals


NEMA vs. IEC Motors

General Overview

§ Fundamental motor operation is the same

§ Both are induction motors

§ National Electrical Manufacturers’ Association (NEMA)

§ Primary standards in the United States

§ Prevalent in Canada, Mexico as well

§ International Electrotechnical Commission (IEC)

§ Most widely adopted standards worldwide§ 67 member countries, including the US

§ IEC defined requirements issued as Directives by the EU§ International standards frequently incorporated into local country

specifications

§ Metric vs. IEC – there is a difference


Merging of Standards

§ Harmonizing of standards required to create a truly global marketplace

§ IEC enclosure and ventilation codes (IC) are now in the NEMA MG standards

§ NEC incorporates IEC hazardous area zone classifications

§ Restriction of Hazardous Substances (RoHS) is an EU directive

§ Does not currently apply to motors

§ Efficiency calculations§ IEC used to assume a fixed value for stray losses, NEMA measures actual values.

§ With the new standard IEC use the same method as NEMA

§ US participation in standards writing is declining

§ Reasonable to expect further infusion of IEC specifications


Aspects for Comparison

§ Power ratings

§ Voltage, frequency & speed

§ Service factor

§ Insulation classes

§ Efficiency

§ Altitude

§ Ambient§ Cooling codes

§ Ingress protection

§ Mounting positions

§ Terminal boxes

§ Frame size designations

§ Output characteristics

§ Dimensions

§ Hazardous areas


Power Ratings

§ NEMA motors rated in horsepower (HP)

§ 1 HP = power to lift 33,000 pounds 1 foot in 1 minute

§ IEC uses kilowatts (kW)

§ HP x 0.746 = kW or kW/0.746 = HP

§ Both NEMA and IEC assign specific power ratings to certain framesizes according to speed

§ In general, output power ratings and frame sizes are comparable

§ There are some exceptions, and in these cases there can be framesize differences to be taken into consideration


Common voltages around the worldVoltage & frequency combinations

50 Hz 220 240 380* 400* 415 500 600 690

60 Hz 230 --- 440 460 480 575 --- ---

Voltage, Frequency & Speed

§ Maximum voltage variation: NEMA ± 10%; IEC ± 5%

§ Maximum frequency variation: NEMA ± 5%; IEC ± 2%

50 Hz 220 240 380* 400* 415 500 600 690

60 Hz 230 --- 440 460 480 575 660

Base speeds based on number of polesSpeed (rpm)

Poles 2 4 6 8 10 12

50 Hz 3000 1500 1000 750 600 500

60 Hz 3600 1800 1200 900 720 600

* Voltages occasionally seen at 60 Hz


Service Factor

§ Definition: Permissible amount of overload a motor will handle within definedtemperature limits without overheating

§ Motor may be loaded according to the value of rated power times service factor

§ Primary uses

§ Compensate for inaccuracy in predicting system power needs

§ Lengthen insulation life by lowering winding temperature at rated load

§ Handle intermittent overloads or unbalanced supply voltages


Service Factor

14.37 APPLICATION OF ALTERNATING-CURRENT MOTORS WITH SERVICE FACTORS14.37.1 GeneralA general-purpose alternating-current motor or any alternating-current motor having a service factor in

accordance with 12.52 is suitable for continuous operation at rated load under the usual service conditionsgiven in 14.2. When the voltage and frequency are maintained at the value specified on the nameplate, themotor may be overloaded up to the horsepower obtained by multiplying the rated horsepower by theservice factor shown on the nameplate.

When the motor is operated at any service factor greater than 1, it may have efficiency, power factor, andspeed different from those at rated load, but the locked-rotor torque and current and breakdown torque willremain unchanged.

A motor operating continuously at any service factor greater than 1 will have a reduced life expectancycompared to operating at its rated nameplate horsepower. Insulation life and bearing life are reduced by theservice factor load.

NEMA Standards Publication MG 1-2006 Revision 1Part 14, Page 12

§ Service factor is not recognized by IEC§ Motors are designed to deliver rated power for an

average lifetime§ Size the motor to the application requirements


International Cooling Codes

§ IC codes are now included in NEMA enclosure type definitions1.26.2 Totally Enclosed Fan-Cooled Machine

A totally enclosed fan-cooled machine is a frame-surface cooled totally enclosed machine equippedfor self exterior cooling by means of a fan or fans integral with the machine but external to theenclosing parts.

1.26.3 Totally Enclosed Fan-Cooled Guarded Machine (IC411)

A totally-enclosed fan-cooled guarded machine is a totally-enclosed fan-cooled machine in which allopenings giving direct access to the fan are limited in size by the design of the structural parts or byscreens, grilles, expanded metal, etc., to prevent accidental contact with the fan. Such openingsshall not permit the passage of a cylindrical rod 0.75 inch diameter, and a probe such as that shownin Figure 1-1 shall not contact the blades, spokes, or other irregular surfaces of the fan.

§ IEC specifies detail using letter& number codes for definition

§ IC 410 – motor w/o fan§ IC 411 – TEFC§ IC 416 – TEBC§ IC 418 – TEAO§ IC 01 – ODP

NEMA Standards

Publication:

MG 12006 Revision 12007

part 1, page 17 & 18


Protection Against Solid Bodies Protection Against Liquid

0 No Protection 0 No Protection

1 Objects > 50 mm 1 Vertically dripping water

2 Objects > 12 mm 2 75o to 90o dripping water

3 Objects > 2.5 mm 3 Sprayed water

4 Objects > 1 mm 4 Splashed water

5 Dust protected 5 Water jets

6 Dust-tight 6 Heavy seas

7 ----- 7 Effects of immersion

8 ----- 8 Indefinite immersion

Ingress ProtectionCode Definitions

Comparative Examples

NEMA Type 1 = IP 10NEMA Type 3 = IP 14NEMA Type 3R = IP 54

NEMA Type 4/4X = IP 55NEMA Type 12 = IP 52NEMA Type 13 = IP 54


Mounting PositionsNEMA Definitions

4.3 MOTOR MOUNTING AND TERMINALHOUSING LOCATIONThe motor mounting and location of terminalhousing shall be as shown in assembly symbolF-1 of Figure 4-6. Where other motor mountingsand terminal housing locations are required,they shall be designated in accordance with thesymbols shown in Figure 4-6.

Assembly symbols F-1, W-2, W-3, W-6, W-8,and C-2 show the terminal housing in the samerelative location with respect to the mountingfeet and the shaft extension.

All mountings shown may not be available for allmethods of motor construction.

NEMA Standards Publication MG 1-2006 Revision 1Part 4, Pages 12 & 13


Terminal Boxes

§ NEMA standard location is on left handside facing output shaft (F1)

§ Optional positions on right hand side(F2) and on top (F0)

§ IEC has no standard, the most commonis on the top (this is ABB standard)§ Optional locations on either side –

left (F1) or right (F2)§ Terminal box can generally be rotated

4 x 90 degrees

§ Terminal posts make for easyconnection of leads

§ Flying leads require extra space toconnect and contain inside


Frame Size Designations

§ First two (2) digits of NEMA frame size designation represent four (4) timesthe actual shaft height in inches

§ EX: 11 inch shaft height x 4 = 44_ frame size

§ IEC motors use actual shaft height in millimeters

§ EX: 280 mm shaft height = 280 frame

§ Most frame sizes in either NEMA or IEC have a comparable equivalent interms of shaft height

§ EX: 280 mm/(25.4 mm/in) = 11.02 inches

§ EX: 11 in x 25.4 mm/in = 279.4 mm

§ One exception – there is a 100 frame IEC motor which has nocomparable NEMA counterpart§ [100 mm/(25.4 mm/in)] x 4 = 15.7 inches => NEMA 160 frame?


Frame SizeDesignation Comparisons

§ IEC defines a wider range

§ 56 through 1000 mm shaft heights

§ No NEMA equivalents for all of them§ NEMA technically stops with 440 frame series

§ Up to 680 frame listed in MG-1 standard

IEC 56 63 71 80 90 100 112 132 160 180 200 225

NEMA --- 42 48 56 140 --- 180 210 250 280 320 360

IEC 250 280 315 355 400 450 500 560 630 710 800 900 1000

NEMA 400 440 500 580 680 700 800 --- --- --- --- --- ---


DimensionsComparisons

§ IEC measurement labels tend to be morelogically defined

§ Length

§ NEMA = C, IEC = L

§ Shaft height

§ NEMA = D, IEC = H

§ Shaft diameter

§ NEMA = U, IEC = D

§ IEC dimensions are in mm, NEMA ininches

§ Many dimensions are very close to thesame

§ NEMA output shaft lengths tend to belonger

§ Shaft heights, foot spacings, shaftdiameters within 3 or 4 mm


Life cycle services for motors,generators and mechanical powertransmission products

Xuan TranAnh, BU Motors and Generators


Our service vision

§ Service will be the key differentiator.

§ Customers will buy ABB products because of our service,

and not service because of the product.


Our service mission

§ We aim to understand our customers better than anybodyelse.§ We believe in passionately serving our customers’ known

and unknown needs and delivering a service experiencethat exceeds their expectations, thereby helping them toachieve their goals.


Our definition of service

§ We define service as any activity that adds value to ourcustomers

§ We offer service solutions that are our main growthproviders and operational excellence that promotesABB’s business both in service and in products.

§ Everything we do, we do safely, sustainably and withintegrity.


ABB Service solutions for different customer‘s needs

To solve problemsquickly and effectivelyto restore its operation

To solve problemsquickly and effectivelyto restore its operation

To increase processreliability to avoidunplanned interruptionin its operation

To increase processreliability to avoidunplanned interruptionin its operation

To optimize operationto increaseproduction capacity

To optimize operationto increaseproduction capacity

§ Technical support§ Emergency field service

resources§ Spares availability§ Onsite and workshop repair§ Training§ Response time contract

§ Installation andcommissioning

§ Preventive maintenance§ Diagnosis, condition

monitoring§ Service contract

§ Engineering and consulting§ Spares rationalization§ Energy, performance and

reliability appraisal§ Upgrade – replacement§ Life cycle costing§ Risk management

Safe

ty

Availability

Optimization

Reliability

What are the customer needs? ABB Service solutions

© ABB Group | BU Motors and Generators

Global presenceGlobal service products, local service centers

August 12, 2012 | Slide 240

Service Partner

Service Center


A schematic motor life cycleTraditional situation without service strategy


A schematic motor life cycleOptimal situation with service strategy in place


Product life cycle management model

ObsoleteLimitedClassicActive

Guaranteed:

Selection & dimensioningInstallation & commissioningTrainingTechnical supportMaintenance & site serviceSpare partsRepairs & refurbish

Guaranteed:

TrainingTechnical supportMaintenance & site serviceSpare partsRepairs & refurbishMigration & upgrading

When available:

TrainingTechnical supportMaintenance & site serviceSpare partsRepairs & refurbishMigration & upgradingReplacement

When available:

Technical supportMaintenance & site serviceSpare parts

Replacement

Guaranteed product support Limited product support

Service offering for the different phases


Installation and commissioning

§ Without a proper installation and commissioningno amount of maintenance will achieve thedesired performance

Benefits for customers§ Electrical work carried out by skilled personnel

only§ Safe and controlled start-up methodology§ Clearly defined procedures for installation and

commissioning (ex: alignment protocol)§ Standard reporting§ Reduction in installation and commissioning

time§ Improvement in process operation and

efficiency§ Warranty protection§ Record of parameters§ Increase of reliability, availability and safety


Spare part categories§ Operational spare parts

§ For commissioning and first years ofoperation

§ Recommended spare parts§ Extended operational spare parts package

§ Capital spares§ In critical applications

Benefits for customers§ Access to original spare-parts§ Expert support in part and capital spares

identification based on motors and generatorscondition and criticality

§ Minimized down-time in case of failure§ Ensure motor and generator availability§ Single source supplier§ On line system – Business OnLine

Spare-parts


Maintenance

§ Reactive maintenance§ Failure or abnormal operation

§ Time based preventive maintenance§ Based on manufacturer’s experience

§ Condition based predictive maintenance§ Maintenance based on actual measurements

Different approach to maintenance


Maintenance

§ Investing in preventing of failure, rather thanliving with its consequences, such as loss ofproduction is primary concern for manybusinesses.

§ Successful prevention of failure can make thedifference whether a company manage to retainits long-term competitiveness

Benefits for customers§ Replaces unplanned disruption with planned

programs so resources can be deployed moreeffectively

§ Proven concept with clear program: L1-L4§ Predefined maintenance kits§ Scheduled according to planned production

stops§ Reduced or eliminated loss of production and

risk of environmental and safety issues§ Reduce the overall cost of maintenance§ Warranty protection

Time based preventive maintenance


Maintenance

§ Maintenance scheduling based on actual condition rather thantime intervals

§ Requires reliable condition monitoring and diagnostic services§ ABB Life Expectancy Analysis Program (ABB LEAP) assesses

the condition of the stator winding insulation in motors andgenerators

§ ABB MACHsense–P offers a comprehensive analysis ofelectromagnetic and mechanical faults in motors like rotorwinding defects, installation problems and bearing defects

§ ABB MACHsense-R (remote service) continuously monitors keyparameters related to the condition of the cage rotor, bearings ofmotors and generators, and it can also address temperatureissues.

§ Site measurements are performed by trained personnel in theABB Service Center network

Benefits for customers§ Comfort in knowing condition§ ABB creates maintenance plans for motors and generators that

helps our customers to§ Minimize unplanned and planned downtime§ Extend motors and generators lifetime§ Reduce operating risks

Condition based predictive maintenance


On site and workshop repair§ The faster a fault can be repaired, the

smaller the consequences.§ ABB offers a range of repair services,

warranty or non-warranty, to providecustomers with a choice depending of thesituation and exact financial and operationneeds.

§ The services include on-site repair by ABB orits certified partners. If an immediate on-siterepair is not required or not possible a repaircan be carried out a ABB’s or its servicepartners workshop facilities

Benefits for customers§ Access to technical documentation for ABB

motors and generators§ Fast response and high quality of work

through ABB’s world wide network of LocalService Centers


Service contract – customized solutions

§ An efficient way to manage the total lifecycle of motors and generators

§ Minimizes risk of customer production§ One or more services combined to

achieve best possible solution for eachcustomer

Benefits for customers§ Tailor made services based on product

condition and importance§ Customizable for customer to suit

needs, giving cost-effective delivery of arange of important benefits, coordinatedunder one single contract


Training

§ Service provides trainings to ABB’scustomers and end users

§ General motor and generatorawareness

§ Maintenance and service§ Training can be tailored to suit customers

needs

Benefits for customers§ Employee confidence and motivation§ Employee competence in maintenance and

first-line trouble shooting§ Competent employees reduces risk of down-

time through the ability to interpret alarmwarnings ands undertake appropriate actionsto avoid failures

§ Gives ability to employees personal tointeract with expert technical support


Replacement

§ When motors and generators are in limited phases, partsmight not be available anymore or repair cannot be done atreasonable costs, replacement is the only solution

§ New standard motors/generators with adaptations§ New standard motor/generator with specific electrical and/or

mechanical design (e.g.: foot print)§ Upgrading or rebuilding of old motors/generators

Benefits for customers§ Reduction in life cycle costs§ Increase of reliability, availability and safety§ Selection based on energy calculations possible§ Access to latest technology§ Expert support in selecting and designing replacement§ Access to original drawing and specification for ABB motors

and generators


§ Technical support through world widenetwork of service centers§ Fast and competent§ Escalation to world leading

experts§ Field engineers available on call out

§ Selection of guaranteed on-siteresponse time

Benefits for customers§ Quick identification of the problem§ Direct service actions to prevent failure

and minimize the consequences§ To help minimize your downtime and

bring the motors/generators back online

§ Possibility to optimize in housemaintenance staff.

Technical support and Emergency field serviceresources


Engineering and consulting

§ Advisory services from experts for life cyclemanagement of motors and generators

§ Energy efficiency and reliability appraisals show thesavings that can be achieved by replacing an existingproduct with a more efficient and reliable unit

§ Transient mitigation services check the susceptibility ofyour network to transients which could damage thestator windings of motors

§ Other solutions are available for dealing with specificproblems that may arise at the site.

Benefits for customers§ Maximized availability and reliability§ Extended lifetime through use of most appropriate

maintenance practices§ Minimized unplanned downtime§ Controlled risks and costs associated with maintenance§ Access to solutions based on patented and specialized

technology§ Single source for consulting services and

implementation of solutions

Service offering can be found atwww.abb.com/motors&generators


motor workshop presentataion files. english

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